Methods and systems for automatically extruding and cutting dough-based products having pre-selected weights

ABSTRACT

A method for automatically forming dough-based products, such as doughnuts involves pressurizing a tank containing dough. The dough is extruded to form a flight of dough-based products. The weight of the flight of dough-based products is measured. The weight data is transmitted to a computer. The measured weight is compared to a predetermined weight stored in the computer memory. The pressure in the tank is adjusted automatically before subsequent extrusions.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This is a continuation-in-part application of pending U.S. patentapplication Ser. No. 09/864,701 filed on May 23, 2001, which isincorporated in full by reference, which claims priority to, andincorporates by reference in full, the following provisionalapplications: U.S. Provisional Patent Application Serial No. 60/238,511,filed Oct. 6, 2000, entitled “Methods and Systems to AutomaticallyControl Extruded Dough-Based Product Weight;” U.S. Provisional PatentApplication Serial No. 60/238,477, filed Oct. 6, 2000, entitled “Methodsand Systems for Automatically Extruding and Cutting Dough-Based ProductsHaving Pre-Selected Weights;” and U.S. Provisional Patent ApplicationSerial No. 60/206,918 filed May 25, 2000, entitled, “Methods andApparatus for Automatically Extruding and Cutting Dough-Like ProductsHaving Pre-selected Weights.”

FIELD OF THE INVENTION

[0002] The present invention relates generally to methods and systemsfor automatically extruding dough-based products having pre-selectedweights. More particularly, embodiments of the present inventionautomatically scale the weight of a dough-based product, such as adoughnut, at the extruder end of an apparatus by controlling theextrusion tank air pressure.

BACKGROUND OF THE INVENTION

[0003] Doughnut production involves mixing and extruding a dough-basedproduct. The extruded dough-based product is cut and dropped onto a beltor tray and transported through a proofer to a frying apparatus forcooking. After cooking, the dough-based product may be glazed, filled,and/or decorated to make the final doughnut.

[0004] A conventional extruding and cutting apparatus is made ofstainless steel plate, industrial construction, and washdown (NEMA IV isa requirement). Such an extruding and cutting apparatus comprises acontainer for the dough, a lid with hold-down screws, and an extrudingmechanism that dispenses the dough-based products at the base of thecontainer. As used herein, the term “extruding mechanism” includes whatis known in the industry as “cutters,” “knives,” or any other extrudingdevice that is used to extrude and cut the dough-based product from thecontainer.

[0005] A conventional extruding and cutting apparatus is constructedsomewhat like a pressure cooker, and the container is airtight when thescrews are tightened and the lid is secured. Once secured, the containeris pressurized to a pre-selected starting air pressure that is based onthe type of dough-based product to be dispensed. Air pressure iscritical to the maintenance of proper dispensed weight of the selecteddough-based product. Next, the extrusion process is initiated and airpressure forces the dough through the cutters as they are opened andclosed by the air cylinder mechanism.

[0006] It is important that dough-based products formed by the extruderhave a constant weight (i.e., a weight within an acceptable range).Operating conditions for subsequent processing steps are set based ondough-based products having a particular weight. When dough-basedproducts are formed by the extruder and have weights outside of a targetrange, then the final product (i.e., after proofing and frying) may haveundesirable properties. For example, the dough-based products may beoutside product specifications, crunchy, too oily, underfried or mayhave a burnt flavor. Dough-based products with these properties may beunsatisfactory to customers.

[0007] In conventional systems, an operator constantly oversees theproduction run and manually weighs the dispensed dough-based products(i.e., individual cuttings of the dough-based product). Based on theactual dispensed weight, the operator adjusts air pressure to maintainthe pre-selected weight of the dough-based products. If a dough-basedproduct is not within the pre-selected dough-based product weight range,then the operator manually, adjusts the air pressure until thepre-selected dough-based product weight range is achieved.

[0008] For example, in a conventional system designed to produce twohundred seventy (270) dozen doughnuts per hour, an operator removes onehalf dozen doughnuts per minute (i.e., one tray or flight ofdoughnuts—six doughnuts being the number of doughnuts formed with eachextrusion) and weighs them. The operator then adjusts the pressure ifthe weight of these six doughnuts are outside of a target weight range.With this system, thirty dozen doughnuts are discarded per hour in orderto insure that doughnuts having a proper weight are formed by theextruder. In addition, the operator may also spend time straighteningthe formed dough-based products on the trays before they are proofed.

[0009] Further, in conventional processes, when the dough supply runslow, one or more of the cutters dispense air. This is referred to as a“blow out.” Thereafter, the operator immediately stops the extrusionprocess.

[0010] Conventional industry practice is a time-consuming, subjective,and imprecise process that demands high labor and product resources.Thus, a need exists for methods and systems to automatically extrude andcut dough-based products while also automatically maintaining apre-selected target weight. A need also exists for methods and systemsthat are able to communicate with other doughnut production devices,such as a proofer or a fryer, and automatically control these deviceswith input/output signals to streamline the entire doughnut productionprocess. There is a further need for state-of-the-art methods andsystems that are user-friendly and that are able to collect, accumulate,disseminate, and manage doughnut production data in a fast, reliable,and efficient manner.

SUMMARY

[0011] To overcome the aforementioned problems and to provide otherbenefits, the present invention provides easy, reliable, and efficientmethods and systems for automatically extruding and cutting dough-basedproducts having pre-selected weights. In an embodiment of the presentinvention, the methods and systems automatically scale the weight ofindividually cut dough-based products dispensed at the extruder end ofan extruder apparatus by directly controlling the extrusion tank airpressure, thereby, controlling the dough-based product weight range.Examples of dough-based products that may be formed using the methodsand apparatuses of the present invention include, without limitation,doughnuts, ring doughnuts, doughnut shells, doughnut holes, doughnuttwists and cinnamon rolls.

[0012] In an embodiment of a method of the present invention forautomatically forming dough-based products, a tank containing dough ispressurized. The dough is extruded and cut into individual dough-basedproducts by an extruding mechanism. In one embodiment, several extrudingmechanisms are connected to the tank, such that an equivalent number ofdough-based products may be formed at the same time. The extrudingmechanisms may be actuated at the same time, so that in one cycle, aflight of individual dough-based products are formed and may be releasedonto trays or other conveying mechanisms.

[0013] According to a method of the present invention, the weight of thedough-based products in each flight is measured. The weight of thedough-based products in each flight may be measured in a number of ways.In one embodiment, the weight of the tank, including its contents, ismeasured after each flight of dough-based products is formed. The weightof the tank after the flight of dough-based products is formed iscompared to the weight of the tank after the formation of the previousflight to determine the weight of the most recently formed flight ofdough-based products. In this embodiment, the tank is attached to atleast one load cell that measures the weight of the tank and itscontents.

[0014] The weight data from the load cells may be transmitted to acomputer having a processor and memory. The measured weight of thedough-based products in the flight is compared to a predetermined weightstored in the computer memory. If the measured weight is different fromthe predetermined weight, the computer may adjust the pressure in thetank. The computer may adjust the pressure in the tank by transmitting asignal to an air pressure controller coupled to a source of airpressure. A software application may perform this comparison anddetermine the size of the pressure adjustment. If the measured weight isthe same as the predetermined weight, no pressure adjustment may benecessary.

[0015] In another embodiment, a predetermined weight range is stored inthe computer memory. In this embodiment, if the measured weight isoutside the predetermined weight range, then the computer may adjust thepressure in the tank. If the measured weight is within the predeterminedweight range, then no pressure adjustment may be necessary.

[0016] The computer may also include a database, which storesdough-based product formulas. The product formulas may be sorted by typeof dough-based product and may include such information as thepredetermined weight, the number of extruding mechanisms and an initialair pressure for the tank.

[0017] In another embodiment of a method of the present invention, datarelating to the measured weight of the dough-based products and pressureadjustment are stored. The stored data may be used in subsequentprocessing steps. For example, the stored data may be used to adjust theprocess parameters of a proofer or a fryer.

[0018] In another embodiment, a method for automatically formingdough-based products comprises adding dough to a tank having a lid andsecuring the lid to the tank. The lid may be secured to the tankmanually or using an automated tank tightener. The tank may then bepressurized. The dough is extruded and cut into individual dough-basedproducts by an extruding mechanism. In one embodiment, several extrudingmechanisms are connected to the tank, such that an equivalent number ofdough-based products may be formed at the same time. The extrudingmechanisms may be actuated at the same time, so that in one cycle, aflight of individual dough-based products may be extruded onto trays orother conveying mechanisms.

[0019] According to a method of the present invention, the weight of thedough-based products in each flight is measured. The weight of thedough-based products in each flight may be measured in a number of ways.The weight of the at least one dough-based product may be compared to apredetermined weight stored in a computer memory. The pressure in thetank may be adjusted based on the weight comparison.

[0020] Methods of the present invention may also comprise specifying atleast one process parameter using an input device connected to thecomputer. In one embodiment, a number of trays to skip after eachextrusion may be specified. For example, a user may specify that doughis to be extruded on every other tray.

[0021] In further embodiments, the method may comprise entering a useridentification means in the computer. The user identification means maybe displayed and may be stored along with data relating to measuredweights of the dough-based products and pressure adjustments. The useridentification means may be required to select dough-based productformulas from a database and/or to modify parameters.

[0022] The present invention also relates to methods for automaticallymaking dough-based products. In one embodiment, dough-based products aremade by pressurizing a tank containing dough, extruding the dough intoindividual dough-based products, proofing the dough-based products andfrying the dough-based products. In this embodiment, after eachextrusion of individual dough-based products, the weight of thedough-based products are measured as discussed above. The weight datamay be transmitted to a computer having a processor and memory. Themeasured weight of the dough-based products may be compared to apredetermined weight stored in the computer memory. Based on this weightcomparison, the computer may adjust the pressure in the tank beforesubsequent extrusions and cuts of dough to form dough-based products. Ina further embodiment, the dough-based products are glazed.

[0023] A software application on a computer in an embodiment comparesthe measured weight of the at least one dough-based product to thepredetermined weight. The software application may also determine thenecessary adjustment, if required, based on the weight comparison. Thecomputer may also include a database containing dough-based productformulas. The product formulas may be sorted by type of dough-basedproduct and may include such information as the predetermined weight,the number of extruding mechanisms and an initial air pressure for thetank.

[0024] In another embodiment, data relating to the measured weight ofthe dough-based products and pressure adjustment are stored. The storeddata may be used to adjust process parameters of the proofer, the fryer,the glazer or other post-extrusion processing equipment.

[0025] An embodiment of an apparatus of the present invention forautomatically forming dough-based products comprises an extruder tankhaving an air inlet. A source of air pressure is connected to the airinlet to control the pressure in the tank. The apparatus also includesat least one extruding mechanism, which may be a cutter, a knife orother extruding device known in the industry that may be used forextruding and cutting dough-based products. In one embodiment, theextruding mechanism extrudes individual dough-based products. Anapparatus of the present invention may be equipped with multipleextruding mechanisms, such that several individual dough-based productsmay be extruded and cut at the same time.

[0026] The extruder tank is positioned on at least one load cell. Theload cells are coupled with a computer having a processor and memory.Data relating to the weight of the extruder tank, including itscontents, are transmitted from the load cells to the computer. An airpressure controller is coupled with the computer and with the source ofair pressure. After receiving the data relating to the weight of theextruder tank, the computer transmits signals to the air pressurecontroller to adjust the pressure in the tank based on the weight data.

[0027] In one embodiment, a database is stored in the memory andincludes data relating to type of dough-based product, target weight ofthe dough-based product, number of extruding mechanisms and initial airpressure in the extruder tank. A user interface device may also becoupled to the computer. The user interface device enables a user todisplay, select and input process parameters and operating conditions.

[0028] In another embodiment, an apparatus of the present invention forautomatically forming dough-based products comprises an extruder tankcomprising a lid and an air inlet, and containing dough. The apparatusmay also comprise means for securing the lid to the extruder tank. Inone embodiment, the means for securing the lid to the extruder tankcomprises an automated lid tightener. A source of air pressure isconnected to the air inlet to control the pressure in the tank. Theapparatus also includes at least one extruding mechanism, which may be acutter, a knife or other extruding device known in the industry that maybe used for extruding and cutting dough-based products. In oneembodiment, the extruding mechanism extrudes individual dough-basedproducts. An apparatus of the present invention may be equipped withmultiple extruding mechanisms, such that several individual dough-basedproducts may be extruded and cut at the same time.

[0029] The extruder tank is positioned on at least one load cell. Theload cells are coupled with a computer having a processor and memory.Data relating to the weight of the extruder tank, including itscontents, are transmitted from the load cells to the computer. An airpressure controller is coupled with the computer and with the source ofair pressure. The air pressure controller, in one embodiment, may be atransducer. After receiving the data relating to the weight of theextruder tank, the computer transmits signals to the air pressurecontroller to adjust the pressure in the tank based on the weight data.

[0030] In one embodiment, a database is stored in the memory andincludes data relating to type of dough-based product, target weight ofthe dough-based product, number of extruding mechanisms and initial airpressure in the extruder tank. A user interface device may also becoupled to the computer. The user interface device enables a user todisplay, select and input process parameters and operating conditions.

[0031] A default setting, in another embodiment, may be stored in thememory and may comprise data relating to global parameters and datarelating to product formulas. The memory may further include a programto restore the default setting.

[0032] The apparatus may also comprise a thermometer. The thermometermay measure, for example, the dough temperature.

[0033] It is a feature and advantage of the present invention to providea method and apparatus for forming dough-based products that provide forthe automatic control of the weight of dough-based products.

[0034] It is another feature and advantage of the present invention toprovide a method and apparatus for forming dough-based products thatrequire less supervision by an extruder operator.

[0035] A further feature and advantage of the present invention is toprovide a method and apparatus for forming dough-based products thatresult in substantial product savings by reducing the amount of doughthat is discarded in order to monitor the weight of the dough-basedproducts.

[0036] A still further feature and advantage of the present invention isto provide a method and apparatus for forming dough-based products thatresult in standardized dough-based products among various stores (i.e.,a ring doughnut made in one store is identical in weight, shape, andappearance as a ring doughnut made in another store).

[0037] An additional feature and advantage of the present invention isto provide a method and apparatus for forming dough-based products thatautomate production line processes and controlling devices usinginput/output signals from multiple indicators to streamline dough-basedproduction from an extruding apparatus to a proofer apparatus to a fryerapparatus.

[0038] A further feature and advantage of the present invention is toprovide a method and apparatus for forming dough-based products thatinclude the automated collection of production data.

[0039] A still further feature and advantage of the present invention isto provide a method and apparatus for forming dough-based products thatenable the tracking of ingredients used to make dough-based products andthe automation of re-ordering the ingredients.

[0040] The method and apparatus of the present invention alsoadvantageously provide for automated shut-down when there is aproduction limitation or problem (e.g., blow out when dough supply islow).

[0041] Another feature and advantage of the present invention is toprovide a method and apparatus for forming dough-based products thatinclude audible alarms to alert an operator, including low product andsafety alarms.

[0042] A further feature and advantage of the present invention is toprovide a method and apparatus for forming dough-based products thatallow for increased production flexibility (i.e., the methods andsystems can be used for a multitude of dough-based products includingdoughnuts, such as, for example, ring doughnuts, shell doughnuts,cinnamon buns, doughnut holes, etc.).

[0043] A still further feature is that the methods and apparatuses ofthe present invention may determine the proper operating pressure at thebeginning of a production run more quickly than an operator adjustingthe pressure by hand.

[0044] Another feature and advantage of the present invention is toprovide a method and apparatus for forming dough-based products thatallow for more precise pressure adjustments.

[0045] A further feature and advantage of the present invention is toprovide a method and apparatus for forming dough-based products thatinclude means for securing an extruder tank lid to the extruder tank.

[0046] A still further feature and advantage of the present invention isto provide a method and apparatus for forming dough-based products thatinclude the ability to measure the temperature of dough in an extrudertank and to make adjustments to the process or process equipment basedon the dough temperature.

[0047] Another feature and advantage of the present invention is toprovide a method and apparatus for forming dough-based products thatimproves production efficiency by allowing the number of dough-basedproducts produced during a given time period to be controlled based oncustomer demand.

[0048] Additional uses, objects, advantages, and novel features of theinvention will be set forth upon review of the drawings and of thedetailed description that follows, and will become more apparent tothose skilled in the art upon examination of the following.

BRIEF DESCRIPTION OF THE DRAWINGS

[0049]FIG. 1 is a flow chart which illustrates an embodiment of a methodof the present invention for forming dough-based products;

[0050]FIG. 2 is a front elevational view of an embodiment of anapparatus for forming dough-based products of the present invention;

[0051]FIG. 3 is a side elevational view of an embodiment of an apparatusfor forming dough-based products of the present invention;

[0052]FIG. 4 is a rear elevational view of an embodiment of an apparatusfor forming dough-based products of the present invention;

[0053]FIG. 5 is a front elevational view of another embodiment of anapparatus for forming dough-based products of the present invention

[0054]FIG. 6 is a front elevational view of one embodiment of anautomated lid tightener;

[0055]FIG. 7 is a front elevational view of a load cell assembly for usein an embodiment of an apparatus of the present invention;

[0056]FIG. 8 is a cross-sectional view of a load cell assembly for usein an embodiment of an apparatus of the present invention taken alongthe line 8-8 in FIG. 7;

[0057]FIG. 9 is a cross-sectional view of a load cell assembly for usein an embodiment of the present invention taken along the line 9-9 inFIG. 8; and

[0058]FIG. 10 is a front elevational view of a user interface deviceuseful in an embodiment of the present invention.

DETAILED DESCRIPTION

[0059] The present invention relates to methods and systems forautomatically extruding and cutting dough-based products havingpre-selected weights. Examples of dough-based products that may beformed using the methods and apparatuses of the present inventioninclude, without limitation, doughnuts, ring doughnuts, doughnut shells,doughnut holes, doughnut twists and cinnamon rolls.

[0060] Embodiments of the present invention provide easy, reliable, andefficient methods and systems for automatically scaling the weight of adough-based product at an extruder end of an extruder apparatus based onpre-selected dough-based product target (predetermined) weights. In anembodiment of the present invention, the methods and systems controldough-based product weights by transmitting data relating to the weightof the dough-based products to a computer that compares the weight datato a predetermined (e.g., desirable) weight and adjusts the extrusiontank air pressure. Other embodiments enable input/output signals tocommunicate and manage other production processes and devices.

[0061] For example, the weight of the dough-based products is measuredand compared to a predetermined weight (e.g., a target weight) of thedough-based products. If the measured or actual weight is greater thanthe predetermined weight, then the computer may reduce the extrusiontank air pressure (i.e., by reducing the air pressure, a smaller amountof dough is extruded from the extrusion tank). If the measured or actualweight is less than the predetermined weight, then the computer mayincrease the extrusion tank air pressure, which increases the amount ofdough extruded from the extrusion tank.

[0062] Referring now to the figures, FIG. 1 is a flow chart illustratingan embodiment of the present invention for forming dough-based products.First, a tank containing dough is pressurized 1. The dough is extruded 2into at least one dough-based product. The weight of the at least onedough-based product is measured 3. Data relating to the weight of the atleast one dough-based product are transmitted 4 to a computer having aprocessor and memory. The weight data are compared 5 to a predeterminedweight stored in the computer memory. Based on the weight comparison,the pressure in the tank is adjusted 6 (or not adjusted if the weightdata and the predetermined weight are the same) before subsequentextrusions. The dough-based products may then proceed for furtherprocessing, such as proofing 7, frying 8 and glazing 9. This embodimentand other embodiments of the present invention are discussed in detailbelow.

[0063] FIGS. 2-4 represent various views of an embodiment of anapparatus 10 of the present invention. FIG. 2 is a front elevationalview of an embodiment of an apparatus 10 for forming dough-basedproducts. FIG. 3 is a side elevational view of the apparatus 10 and FIG.4 is a rear elevational view. The operation of the apparatus 10 isdescribed below in connection with the methods of the present invention.

[0064] In an embodiment of a method of the present invention forautomatically forming dough-based products, a tank 12 containing doughis pressurized. The tank 12 preferably has a screw down lid 14 in whichmixed ingredients (e.g., dough) are loaded and sealed. The dough may beadded to the tank in a number of ways. In one embodiment, the dough isloaded in the tank 12 using a hopper when the tank lid 14 is open.

[0065] The tank 10 has an air inlet, which allows air to enter the tank12 and pressurize it. The air may be supplied from a number of sources,such as portable compressors or house air originating from a largecompressor (e.g., air that is supplied to an entire facility). Thesource of air may be coupled to an air pressure controller 65 and an airinput 15 to regulate the amount of air that enters the tank 12 based onsignals from a computer 50. The initial air pressure in the tank 12depends on the types of dough-based products being formed. For example,an acceptable initial air pressure for the production of ring doughnutsis twenty-four (24) pounds per square inch (psig). After dough is loadedinto the tank 12 and the tank lid 14 is sealed, the tank 12 may bepressurized to the initial air pressure.

[0066] The dough is extruded and cut into individual dough-basedproducts by an extruding mechanism 25, typically positioned at thebottom of the tank 12. An example of an extruding mechanism 25 useful inthe present invention is a tube and a cutter arrangement. During a timedsequence or line size, the cutters at the bottom of the extruder open(i.e., the sleeves move up exposing a specified length of the centershaft). The dough is pushed out through the series of openings by theair pressure during a specified period of time (typically, 0.75seconds). Dough-based product size and shape are determined by the airpressure and cutter design. In one embodiment, several extrudingmechanisms 25 are connected to the tank 12, such that an equivalentnumber of dough-based products may be formed with each cycle. The sizeof the tank 12 and likewise, the extruder apparatus 10, may varydepending on the number of extruding mechanisms 25. For example, thesmallest tank may only have two extruding mechanisms while the largestmay have twelve. Typically, the extruding mechanisms 25 are gaugedtogether and are actuated by a single air cylinder. The extrudingmechanisms 25 may be actuated at the same time, so that in one cycle, aflight of individual dough-based products are formed and may be releasedonto trays or other conveying mechanisms. The trays or other conveyingmechanism carry the dispensed dough-based product to a proofer or otherprocessing device.

[0067] According to the method of the present invention, the weight ofthe dough-based products in each flight is measured. The weight of thedough-based products in each flight may be measured in a number of ways.In one embodiment, the weight of the tank 12, including its contents, ismeasured after each flight of dough-based products is formed. The weightof the tank 12 after the flight of dough-based products is formed iscompared to the weight of the tank 12 after the formation of theprevious flight to determine the weight of the most recently formedflight of dough-based products. In one embodiment, the tank 12 isattached to at least one load cell that measures the weight of theextruder tank 12, the air pressure and the mixed ingredients (e.g.,dough). The total weight is recorded between strokes of the extruderapparatus (i.e., after each extrusion to form dough-based products).Each weight is subtracted from the previous weight to determine theweight of the formed dough-based products.

[0068] Load cells useful in the present invention include Model NumberSASC-767, commercially available from J. A. King of Greensboro, N.C.This particular load cell is rated to support a weight of two hundredfifty (250) pounds. In the embodiment of the present invention shown inthe Figures, three load cells 30, 35, 40 are utilized. The load cells30, 35, 40 are positioned such that they support the weight of the tank12 and any dough in the tank. With three load cells, two load cells 30,35 may be positioned on each side of the extruder apparatus 10 and oneload cell 40 is positioned in the back of the extruder apparatus 10. Inother embodiments, four load cells may be used, with a load cellpositioned at each corner.

[0069] The weight data from the load cells 30, 35, 40 may be transmittedto a computer 50 having a processor and memory (e.g., a weightindicator). An example of a useful computer in the present invention isa weight indicator, such as Model Number WI-130 manufactured byWeightronix. The computer 50 may include various software applicationswritten to execute the steps of the present invention. Using thecomputer 50, including the software applications, the measured weight ofthe dough-based products in the flight is compared to a predeterminedweight stored in the computer memory. If the measured weight isdifferent from the predetermined weight, the computer 50 may adjust thepressure in the tank 12. The computer 50 may adjust the pressure in thetank 12 by transmitting a signal to an air pressure controller 65coupled to a source of air pressure. If the measured weight is the sameas the predetermined weight, no pressure adjustment may be necessary. Inanother embodiment, a predetermined weight range may be stored in thecomputer 50. If the measured weight is outside of the predeterminedweight range, then the computer 50 may adjust the pressure in the tank12. If the measured weight falls within the acceptable range, nopressure adjustment may be necessary.

[0070] A software application performs this comparison and determinesthe size of the pressure adjustment. The software application uses acontrol algorithm to determine the amount of pressure adjustment. Anynumber of control algorithms might be used, such as least squares orlinear regression. The computer program uses the actual production data(e.g., the actual dispensed weight of the dough-based products) receivedfrom the at least one load cell and compares it to the control algorithmprogrammed into the system that is based on one or more parameters(e.g., a target weight range) that are associated with a particularproduction run. As will be discussed below, the memory of the computer50 may include a database with parameters stored for each type ofdough-based product. If the weight of the product is different from thetarget weight, then the system adjusts the air pressure in the extruderapparatus 10 before extruding the next flight of dough-based products.

[0071] In one embodiment, the software application determines the newpressure (the pressure including an adjustment based on the prior weightof the dough-based products) using the following formula:${{New}\quad {Press}} = {{{Last}\quad {Press}} - {\left( \frac{{ActualWt} - {TargetWt}}{TargetWt} \right)\left( {{Last}\quad {Press}} \right)({FeedbackAdjustment})}}$

[0072] The actual weight (ActualWt) is the measured weight of theextruded dough-based products. The target weight (TargetWt) refers tothe desired weight of the dough-based product that is also stored in adatabase. The last pressure (LastPress) is the air pressure in the tankfor the extrusion that formed the dough-based products with the actualweight. The feedback adjustment is a specified parameter that correlatesthe difference in weight to the pressure adjustment. The feedbackadjustment is typically expressed as a percentage and any percentage maybe used in order to achieve a desired result. In one embodiment, thefeedback adjustment may be between zero and fifty percent. In otherembodiments, the feedback adjustment is greater than fifty percent andmay be greater than one hundred fifty percent.

[0073] For example, a particular doughnut may have a target weight of1.17 ounces per doughnut with six doughnuts being formed during a singleextrusion (TargetWt=7.02 ounces). Further, the feedback adjustment forthe extruder may be set at 25% or 0.25 (FeedbackAdjustment). After thetwentieth extrusion, the pressure in the tank may be 22 psig(LastPress). The weight of the tray or flight of doughnuts formed by thetwenty-first extrusion may be 1.3 ounces per doughnut or 7.8 ounces(ActualWt). Using the formula above, the tank pressure will be adjustedsuch that the tank pressure prior to the twenty-second extrusion will be21.39 psig.

[0074] The computer 50 may include a database, which stores dough-basedproduct formulas. The product formulas may be sorted by type ofdough-based product and may include one or more of the followingparameters: (1) identification of the particular dough-based product(e.g., ring doughnut, shell doughnut, cake doughnut, doughnut holes,etc.); (2) the number of cutters or extrusion mechanisms used during theextrusion of the dough (i.e., the number of dough-based products in aflight); (3) the individual predetermined dough-based product weight(e.g., a ring doughnut may have a target weight of 1.17 ounces); (4) thepredetermined dough-based product weight range per dozen (e.g., a dozenring doughnuts may weigh 14.04 ounces); (5) initial air pressure for thetank; and (6) a number of trays to skip after each extrusion.

[0075] In an embodiment where a parameter in the product formula is thenumber of trays to skip after each extrusion, the user may utilize thisparameter to specify the number of trays to skip between extrusions. Asnoted above, the extruding mechanisms may be actuated to form andrelease a flight of individual dough-based products onto trays or otherconveying mechanisms. In an embodiment where trays are utilized toconvey the extruded dough-based products, the computer can control thenumber of trays to skip before the next flight of dough-based productsare extruded (i.e., the number of trays to skip between extrusions). Inone embodiment, the trays and skipped trays may be counted usingtechniques known to those of ordinary skill in the art. For example, inembodiments where the trays are transported using a chain, belt, orother endless conveyor-type arrangement, a cam having at least one lobemay rotate as the trays pass. As the cam rotates, the at least one lobemay contact a solenoid when transmits a signal to the computer. In otherembodiments, a light beam may be used to count the trays. In otherembodiments, a proximity switch may be used. The computer may beprogrammed with data relating to the trays (e.g., the rate at which thetrays travel, the dimensions of the trays, and/or the amount of timethat would elapse between extrusions if dough-based products wereextruded on each tray).

[0076] If a user specifies that zero trays are to be skipped betweenextrusions, then the extruding mechanisms will be actuated to form andrelease a flight of individual dough-based products onto each tray. Inone embodiment, the default number of trays to skip for each formula maybe zero. If a user specifies that one tray is to be skipped betweenextrusions, then the extruding mechanisms will be actuated to form andrelease a flight of individual dough-based products onto every othertray. If a user specifies that two trays are to be skipped betweenextrusions, then the extruding mechanisms will be actuated to form andrelease a flight of individual dough-based products onto a first tray,skip two trays, form and release a flight of individual dough-basedproducts onto a fourth tray, skip two trays, etc.

[0077] The ability to specify the number of trays to skip betweenextrusions advantageously allows a user to control the production rateof the dough-based products. For example, if the apparatus is in aretail store and the manager knows that the store sells fewerdough-based products during certain times of the day, the manager mayspecify that a certain number of trays are to be skipped when extrudingthe dough-based products. By skipping trays, the manager reduces therate of production while still producing fresh dough-based products forthe customers that do arrive during the slow production period.

[0078] The computer also may include a user interface device. As usedherein, the term “user interface” includes, without limitation, theterms user interface display, control panel, controller, control panel,control pad, operator panel, and other terms that describe a screen toview, select, and enter information related to the extruder apparatus,cutters, dough-based product, dough-based product weight, etc. With auser interface device, a person using an apparatus of the presentinvention may select a formula for a particular dough-based product ormay define the parameters for a particular production run. Theembodiment of the present invention shown in FIG. 2 includes a computer50 having a display 55 and user input means 60. In another embodiment, aformula may be selected or parameters may be defined from a remoteterminal and communicated to the computer over a network.

[0079] In one embodiment, a user may be required to enter anidentification number, an identification code, a password, or similaruser identification means before the user can access the computer. Forexample, the computer may ask the user to enter an identification numberbefore selecting a formula or modifying a parameter. The computer mayalso ask the user to enter an identification number in order to changeproduct formulas, to add or delete product formulas, and/or to modifysystem parameters. If the user enters a valid identification number, thecomputer may allow the user to operate the computer. If the user doesnot enter a valid identification number, the user may not operate thecomputer. In a further embodiment, the computer may store data relatingto a user's operation of the apparatus (e.g., number of tanks filledduring a given shift, number of cuts made per tank, etc.).

[0080] It may be desirable for the computer to store global parametersin addition to parameters associated with dough-based product formulas.These global parameters are the same for any product formula selected.Such global parameters may include, for example: (1) the number ofcutters on the extruder; (2) the number of samples for a particularcontrol algorithm (e.g., the number of samples for a least squares fitslope calculation); (3) the minimum number of cycles before a pressureadjustment; (4) the maximum tank pressure; (5) the time after the cutteror extruding mechanism closes (i.e., after a product is formed) beforethe weight is measured; (6) the time that the cutter or extrudingmechanism remains open; (7) the percentage to adjust the pressure by;(8) the amount of idle time before a screen saver is activated; (9) apassword; and (10) the enablement of blowout detection (discussedbelow). In other embodiments, these parameters may be separately storedwith each product formula. These global parameters may be set ormodified by an operator with a user interface device located at theapparatus or by a person at a remote terminal sending instructions tothe computer over a network.

[0081] In another embodiment, the computer may include a defaultprogram. The default program may restore the global parameters, theproduct formulas, and other parameters to a default setting. Thus, thedefault program acts as a back-up should any parameter or productformula be changed. For example, if a user inadvertently modifies aglobal parameter that adversely affects production, the user may restorethe computer to its default settings by running the default program. Thedefault program may be particularly helpful if a user does not know whatparameter was changed. In one embodiment, the default program is storedin the computer's memory. A user may need a special password in order torun the default program and restore the default setting.

[0082] The user interface display 55 may display one or more parametersfor an operator of the apparatus to view. Examples of such parametersthat may be displayed include, without limitation: (1) the targetproduct weight (i.e., a predetermined weight); (2) the current productweight (i.e., actual or measured weight); (3) the formula in use (e.g.,a formula number and name); (4) the number of dispensed cycles so far;(5) the accrual weight of the dough; (6) whether blowout detection isenabled; (7) a stop softkey and a restart softkey, which will allow arestart on a false detection of blowout; and (8) an employeeidentification number or code.

[0083] In one embodiment, the product formulas and global parameters arepassword protected. By requiring a password to modify the formulas andparameters, a company may restrict access such that only authorizedpersonnel may make changes.

[0084] As discussed above, the weight data from the load cells 30, 35,40 are transmitted to the computer 50. The measured weight of thedough-based products in the flight is compared to a predetermined weightstored in the computer memory. If the measured weight is different fromthe predetermined weight, the computer 50 may adjust the pressure in thetank 12. If the measured weight is the same as the target weight, nopressure adjustment may be necessary. In another embodiment, apredetermined weight range may be stored in the computer. In thisembodiment, if the measured weight is outside of the predeterminedweight range, then the computer adjusts the pressure in the tank. If themeasured weight is within the predetermined weight range, then nopressure adjustment is made.

[0085] The computer 50 may adjust the pressure in the tank bytransmitting a signal to an air pressure controller 65 coupled to asource of air pressure 20. When the computer used is Model Number WI-130from Weightronix, the air pressure controller should be capable ofaccepting a 4-20 milliamp input and controlling pressure, such that asignal of four milliamps corresponds to a pressure of zero psig and asignal of twenty milliamps corresponds, to maximum pressure. An exampleof an air pressure controller useful in the present invention is a MACvalve, such as Model No. 825C-PM-501-JA-572 commercially available fromMAC Valve, Inc. of Wixom, Mich. In this embodiment, the air pressurecontroller may also include other valves and an air cylinder incommunication with the MAC valve. The source of air pressure may becoupled to the air cylinder. An example of an air cylinder useful in thepresent invention is a Bimba cylinder, such as Model Number J1F80,commercially available from Scott Equipment, Inc. of Huntsville, N.C.

[0086] In other embodiments that utilize a Weightronix Model NumberWI-130 computer, the air pressure controller may be a transducer. In oneembodiment, a transducer useful in the present invention is capable ofaccepting a 4-20 milliamp input and controlling pressure, such that asignal of four milliamps corresponds to a pressure of zero psig and asignal of twenty milliamps corresponds to maximum pressure. An exampleof a transducer useful as an air pressure controller in the presentinvention is an Efector #500 transducer, Model # PA3226, commerciallyavailable from IFM Efector Inc. of Exton, Pa. In this embodiment, theair pressure controller may also include other valves and an aircylinder in communication with the transducer. The source of airpressure may be coupled to the air cylinder. An example of an aircylinder useful in the present invention is a Bimba cylinder, such asModel Number J1F80, commercially available from Scott Equipment, Inc. ofHuntsville, N.C.

[0087] The air pressure controller 65 receives a signal from thecomputer 50, which instructs the controller 65 to allow additional airinto the extruder tank 12 or to release air from the extruder tank 12.For example, if the computer 50 determines that the air pressure in thetank 12 needs to increase, the computer 50 will transmit a signal to theair pressure controller 65 and the air pressure controller 65 will allowmore air to enter the tank 12. Using a Weightronix computer, thesoftware will instruct the MAC valve or the transducer to allow air toenter the tank.

[0088] In a further embodiment of a method of the present invention,electronic dough-based production data is collected, transmitted, storedand used for useful decisions. This production data may be used to (1)provide one or more useful reports; (2) track ingredients used to makedough-based products; (3) automate re-orders; (4) automate shut downwhen the dough supply is low; (5) automate audible alarms to alert anoperator, including low product and safety alarms; and/or increaseproduction flexibility. For example, data relating to the measuredweight of the dough-based products and pressure adjustment may bestored. This stored data may be used to adjust the process parameters ofa proofer (e.g., proofer humidity, proofer temperature, proofer runtime, etc.) or the process parameters of a fryer (e.g., fryertemperature, fryer run time, etc.).

[0089] In another embodiment, a method of the present invention maycomprise determining when the supply of dough in the tank 12 is low. Oneway in which this may be accomplished is by monitoring the pressure inthe tank 12 for pressure loss. When the amount of dough in the tank islow, one of the extruding mechanisms 25 may not have enough dough toextrude a dough-based product. If there is not enough dough to fill anextruding mechanism 25, then air will escape through the extrudingmechanism 25 and a loss of pressure in the tank 12 will occur. Thus, aloss of pressure is an indication that the supply of dough in the tank12 is low.

[0090] The tank 12 may be monitored for pressure losses using a detectoror sensor in the tank 12. The pressure loss detector may not beactivated (i.e., may not begin monitoring) until a predetermined numberof cuts or extrusions have occurred. In a further embodiment, the numberof extrusions or cuts may be counted. The number of extrusions or cutsmay be counted using an input/output module, such as the OPTO 22 I/Omodule commercially available from OPTO of Temecula, Calif. Theinput/output module receives a pulse each time the extruding mechanismcycles. The input/output module is in communication with the computer 50and the number of cycles may be displayed on a display 55 of thecomputer 50 in real time. Further, the computer 50 activates thepressure loss detector when a predetermined number of cuts or extrusionshave occurred and the system begins looking for a blowout.

[0091] As noted above, in one embodiment, blowout detection is a globalparameter and a user may specify whether it should be enabled ordisabled. Similarly, the user interface device may display whetherblowout detection is enabled. The formula for each dough-based productmay specify the number of cuts before the pressure loss detector isactivated.

[0092] As opposed to using a pressure loss detector in the tank todetect blowouts, an alternative embodiment involves using a digitaloutput provided by the air pressure controller 65. In this embodiment,the digital output indicates that an air pressure consistent with ablowout has been achieved.

[0093] In additional embodiments, the computer 50 may trigger certainevents when a blowout is detected. For instance, the computer 50 maystop the extruder apparatus when a blowout is detected by transmittingan output signal. Likewise, the computer 50 could also transmit anoutput signal that would sound an alarm when a blowout is detected.Alternatively, the computer 50 could be programmed to trigger the alarmafter the pressure loss detector is activated. The alarm would alert anoperator, who could be working on other tasks, to return to the extruderapparatus 10 and prepare to start a new production run or stopproduction.

[0094] In another embodiment of the present invention, an operator maychoose to disconnect the system (i.e., disconnect pneumatic hoses fromair pressure controller, turn off the computer, etc.) and operate thesystem manually. In this embodiment, conventional valves and pressureadjusting devices remain installed on the extruder. By reconfiguring thepneumatic hoses, the operator may bypass the automatic system andcontrol the extruder manually.

[0095] In further embodiments of methods of the present invention, afterextrusion, the dough-based products may be proofed at a proofer usingmethods and apparatuses known to those of ordinary skill in the art.After proofing, the dough-based products may transported to a fryerwhere they are cooked using methods and apparatuses known to those ofordinary skill in the art. After the dough-based products are fried,they may be transported for additional processing. In some embodiments,the dough-based products may be glazed in accordance with methods andapparatuses known to those of ordinary skill in the art. The dough-basedproducts may also be iced. If the dough-based products are doughnutshells, they may be filled with a jelly or cream filling.

[0096] In the embodiment shown in FIGS. 2-4, the apparatus 10 comprisesan extruder tank 12 having an air inlet 15. A source of air pressure 20is connected to the air inlet 15 to control the pressure in the tank 12.While the air inlet 15 is shown at the top of the apparatus 15 in thefigures, it may be positioned at any convenient location. The source ofair pressure 20 may be a portable air compressor, a blower or house airoriginating from a large compressor (e.g., air that is supplied to anentire facility). The tank preferably has a screw down lid 14 in whichmixed ingredients (e.g., dough) are loaded and sealed. The tank 12 mayalso be equipped with a pressure gauge 22 for an operator to monitor theair pressure. In some circumstances, the operator may desire to disablethe automatic formation of dough-based products using the method of thepresent invention and may revert to manual operation. Under manualoperation, the operator may monitor the air pressure using the gauge 22.A bar 24 extends across the front of the apparatus 10 and assists inpreventing the apparatus 10 from spreading due to its placement on loadcells.

[0097] The apparatus 10 also includes at least one extruding mechanism25, which may be cutters, knives or other extruding devices known in theindustry that may be used for extruding and cutting dough-basedproducts. In one embodiment, the extruding mechanism 25 extrudes andcuts individual dough-based products. An apparatus of the presentinvention may be equipped with multiple extruding mechanisms, such thatseveral individual dough-based products may be extruded and cut at thesame time. As shown in FIGS. 2-4, the apparatus 10 includes sixextruding mechanisms 25. In this embodiment, six dough-based productsare formed with each cycle of the extruding mechanisms 25. Thedough-based products are formed simultaneously and are released ontotrays or another conveying mechanism.

[0098] In another embodiment of the present invention, the extrusionapparatus has optional “baffles” which may be installed inside thepressure chamber to block dough flow to some of the extrudingmechanisms. The baffles may be used during low traffic times of day toreduce the rate of production. The dough-based products may be producedin odd or even numbers. In an embodiment of the present invention, thedough-based composition and cutters can be arranged to produce at leastfour products—rings, shells, cinnamon buns, and doughnut holes. Each ofthese products has different target weights.

[0099] The extruder tank 12 is positioned on at least one load cell. Inthe embodiment shown, the tank 12 is positioned on three load cells 30,35, 40. Two load cells 30, 35 are positioned on each side of theapparatus 10 and a third load cell is positioned in the back of theapparatus 10. A bar 45 extends across the back of the apparatus andprovides the load for the rear load cell 40. The rear load cell 40 iscentered and bolted to the bar 45. The load cells are coupled with acomputer 50 having a processor and memory. The computer 50 may include adisplay 55 for an operator to view, for example, dough-based productformulas, global parameters or production data. The computer 50 may alsoinclude user input means 60 (e.g., a keyboard, mouse, touchscreen, touchpad, softkeys, etc.) to allow an operator to navigate menus, enterformulas, view production data, enter or view global parameters, etc.

[0100] An air pressure controller 65 is coupled with the computer 50 andwith the source of air pressure 20. The air pressure controller 50receives signals from the computer 50 indicating pressure adjustmentsthat need to be made. If the air pressure needs to increase, the airpressure controller 50 allows air to enter the tank 10. For example, aWeightronix computer communicates a milli-amp signal to the air pressurecontroller and the air pressure controller converts the signal to apressure command to open to either release or add pressure to the tankbased on the command. As noted above, the air pressure controller maybe, for example, a MAC valve or a transducer.

[0101] A thermometer 67 is positioned in the tank 10, as shown in FIG.2. The thermometer 67 monitors the temperature of the dough in the tank10. An example of a thermometer useful in the present invention is aresistance temperature detector, such as Model NumberRB115S6125100PT1723AA, commercially available from GIC ThermoDynamicsInc. of Royal Oak, Mich.

[0102] In one embodiment, the thermometer 67 is in communication with atransmitter 68, which receives data from the thermometer 68 and maydeliver it to the computer 50 or to another computer or piece ofprocessing equipment. An example of a transmitter useful in the presentinvention is resistance temperature detector transmitter, such as ModelNumber TX 1501, commercially available from Omega Engineering ofStamford, Conn.

[0103] The temperature data may be collected, transmitted, stored andused in a number of ways. The temperature data may be used, for example,to make pressure adjustments in the extruder tank and/or to makeadjustments to other process steps or equipment. For example, thetemperature data may be used to set the initial air pressure in thetank. If the dough has a certain temperature when initially placed inthe tank, the computer may correlate a preferred initial air pressure tothat temperature.

[0104] As noted above, the tank 12 preferably has a screw down lid 14.Mixed ingredients (e.g., dough) are added to the tank 12 and the lid 14is secured and sealed to the tank 12. In the embodiment shown in FIGS.2-4, the lid 14 is secured and sealed to the tank 12 by two hand wheels69, which tighten screws into corresponding receptacles on the lid whenturned. The hand wheels 69 are manually turned to tighten the lid.

[0105] In another embodiment of the present invention, the lid 14 may betightened using automated lid tighteners. FIG. 5 is a front elevationalview of the same embodiment of an apparatus for forming dough-basedproducts of the present invention as shown in FIG. 2, except FIG. 5includes two automated lid tighteners 72. FIG. 6 is a front elevationalview of one embodiment of an automated lid tightener 72.

[0106] Referring now to FIG. 5, two lid securing bars 71 are positionedover the lid 14. When the lid 14 is to be opened, the lid securing bars71 rotate toward their respective sides (away from the middle of the lid14) to allow the lid 14 to be raised. When in a vertical position (asshown in FIG. 5), the lid securing bars 71 may secure the lid 14 usingthe automated lid tighteners 72. The automated lid tighteners 72 areheld on lid securing bar 71 by a clamp 73. A cylinder 75 is attached toeach clamp 73 and is fitted to hold a motor 77 associated with eachautomated lid tightener 72. The motor 77, when activated, turns a shafthaving a counterbored locking device (shown in FIG. 6). When thecounterbored locking device is rotated by the motor 77 in a lid closingdirection, the locking device threads through the lid securing bars 71and makes contact with the lid 14. After contact with the lid 14, thelocking device continues to turn and torques down on the lid based onthe air pressure delivered to the motor 77 for torquing.

[0107] As shown in FIG. 6, one embodiment of an automated lid tightener72 comprises a motor 77, a shaft 79 extending from the motor 77, asocket 81 having an allen wrench extension 83 secured to the shaft 79,and a counterbored locking device 84 secured to the allen wrenchextension 83. In one embodiment, the motor 77 is a motorized butterflyair wrench, which can turn the shaft 79 in either radial direction. Anexample of a motorized butterfly air wrench useful in embodiments of thepresent invention is Model No. 5Z 118, manufactured by Westward Tools ofLake Forest, Ill. This model butterfly wrench is a three-eighths inch(⅜″) wrench that can turn at 11,000 rpm and operates at psig. The motor77 preferably also includes a shaft 79 to which the socket 81 may beattached.

[0108] The socket 81 having an allen wrench extension 83 may be anine-sixteenths inch ({fraction (9/16)}″)×three-eighths inch (⅜″) drivesocket, which is generally available at most hardware stores. The allenwrench extension 83 may be a nine-sixteenths inch ({fraction (9/16)}″)allen wrench, which is generally available at most hardware stores. Theallen wrench extension 83 may be secured to the socket 81 by a rollpin.

[0109] The counterbored locking device 84, in one embodiment, may beprepared from a one inch (1″) diameter set screw with approximatelyeight threads per inch. In one embodiment, the counterbored lockingdevice 84 is two and one-half inches (2.5″) long. Other sizes andlengths may be used so long as the automated lid tightener sufficientlyseals the lid to the tank. One end of the counterbored locking device 84should be bored in order to receive the allen wrench extension 83. Thecounterbored locking device 84 may be secured to the allen wrenchextension 83 to prevent the counterbored locking device 84 from slidingoff of the allen wrench extension 83 using the clamp 73 and the cylinder75, which is fitted to hold the motor 77. The counterbored lockingdevice 84 is clamped in place when the motor 77 is mounted on the lidsecuring bar 71.

[0110] A plate tip 85 at the end of the counterbored locking device 84may be welded to the other end of the locking device 84 (the end thatcontacts the lid 14) and provides a surface for closing the lid. Theplate may be a solid piece of #302 stainless steel and may be welded inplace with a three-sixteenths inch ({fraction (3/16)}″) tip in itssurface.

[0111] Once assembled, the motor 77 rotates the shaft 79, which rotatesthe socket 81 having the allen wrench extension 83, which rotates thecounterbored locking device 84. If the motor 77 is powered by air, themotor is preferably connected to a source of air. When operated in onedirection, the motor 77 tightens the lid 14 on the tank 12. The motor 77may be operated in a second direction to loosen the lid 14 so that moredough may be added to the tank 12. As shown in FIG. 5, an assembledautomated lid tightener 72 fits into a cylinder 75, which is attached toa clamp 73. The automated lid tightener 72 may then be used to tightenor loosen the lid as described above.

[0112] FIGS. 7-9 represent different views of a load cell assembly 100for use in an embodiment of an apparatus of the present invention. Loadcell assemblies useful in the present invention are commerciallyavailable from J. A. King Co. of Greensboro, N.C. FIG. 7 is a frontelevational view of the load cell assembly 100. The load cell assembly100 is attached to the extruder apparatus 105 and measures the weight ofthe tank, and any dough or air inside the tank.

[0113]FIG. 8 is a cross-sectional view of a load cell assembly 100 foruse in an embodiment of an apparatus of the present invention takenalong the line 8-8 in FIG. 7. FIG. 8 shows the bottom plate 102, a loadcell assembly cover 104, four mounting bolts with spacers 120, 125, 130,135, a load cell 110, two load cell mounting bolts 112, 114, a carrier115, and a strain relief access port 140. The strain relief access port140 is provided to prevent the pinching and cutting of electrical wirescoming out of the load cell assembly 100.

[0114]FIG. 9 is a cross-sectional view of the load cell assembly 100showing many of the same components illustrated in FIG. 8. FIG. 9 alsoshows two spacers 145, 150 for the load cell mounting bolts 112, 114, aspring overload 155, and a cable 160 for transmitting weight data to acomputer.

[0115] In one embodiment, such as the one shown in FIGS. 8 and 9, thecarrier 115 is a cable having a diameter of three-sixteenths of an inch({fraction (3/16)}″). In other embodiments, the carrier may be a cable,having a diameter of three-thirty-seconds of an inch ({fraction(3/32)}″) and having an exposed length of one-half of an inch ({fraction(1/2)}″). A portion of the unexposed length of the cable may besurrounded by cylinder having a length of one-half of an inch ({fraction(1/2)}″). The cylinder limits the side-to-side or lateral movement ofthe cable. The longer and smaller diameter cable provides moreflexibility while the cylinder provides structural rigidity.

[0116] The mounting bolts 120, 125, 130, 135 secure the bottom plate 102(and the load cell assembly) to extruder frame 105. The loadcell 110 issecured to the bottom plate 102 by the load cell mounting bolts. Thecarrier 115 is connected to the bottom of the extruder frame 105, suchthat as dough is extruded and the tank becomes lighter, the carrier 115pulls the tank closer to the bottom plate 102 by virtue of the springoverload 155. The load cell 110 detects the amount of movement by thecarrier 115 after each extrusion and transmits weight data to acomputer. This weight data is transmitted to a computer by the cable160. The computer converts the weight data signal from the load cell 110to weight and may produce a weight digital output to a user interfacedisplay.

[0117] The following discussion illustrates an example of how a methodor system of the present invention may operate an extruder for one tankof dough. An operator loads the extruder tank with dough. Using an userinterface device, the operator enters and employee identification numberand then selects a product formula from a Main Screen. FIG. 10illustrates an example of a user interface device 200 useful in anembodiment of the present invention. The user interface device 200includes a display 205 and a number of touch keys for an operator toinput requests. The touch keys include a numeric keypad 210, a row ofsoft keys 215 and various function keys 225. The row of soft keys 215are positioned just below a menu 220 on the display 205. Since the menuchanges (e.g., after an operator makes a selection), the functions ofthe different soft keys 215 also change. The functions keys 225 performvarious tasks, such as clearing a user input (“CLEAR”), changing unitson the display (“UNITS”) and entering a user input (“ENTER”).

[0118] On a main screen, the operator selects a product formula bypressing a soft key corresponding to “FORM” (i.e., formula) on thedisplay. The computer, via the display, asks the operator to specify aproduct formula. The operator may choose from any number of productformulas that are stored on the computer. The operator enters a numbercorresponding to a particular product formula. If the formula is defined(i.e., stored on the computer), then the computer displays the formulaname. If the formula is not defined a message, such as “Current FormulaUndefined,” is displayed to the operator. A setup screen allows for theentry of new formulas and for the editing of existing formulas, althoughaccess to these features may be restricted such that only the operator'ssupervisor may modify the product formulas or add new product formulas.

[0119] After selecting a valid product formula, the operator presses asoft key corresponding to “START” on the display to prepare for aproduction run. The computer displays additional information about theproduct formula selected (e.g., weight per dough-based product, numberof extruding mechanisms, whether any baffles are installed and startingpressure). The operator then ensures that the extruder tank lid of theextruder apparatus is closed and securely fastened. The operator pressesa soft key corresponding to “PRESS” on the display to pressurize thetank to the initial or starting pressure as specified in the productformula.

[0120] After pressurization, the operator presses a soft keycorresponding to “START” to begin the production run. The user interfacedevice shows the current dough-based product weight (e.g., ounces perproduct), the formula name, the pre-selected dough-based product weight(e.g., target weight), and the cycle number. A cycle is the processbetween signals from the conveyor cam switch that allows the extruderapparatus to automatically extrude the dough-based products.

[0121] The system includes a number of global parameters, parametersthat are the same regardless of what product formula is selected. Suchglobal parameters include, for example: (1) the number of cutters on theextruder; (2) the number of samples for a particular control algorithm(e.g., the number of samples for a least squares fit slope calculation);(3) the minimum number of cycles before a pressure adjustment; (4) themaximum tank pressure; (5) the time after the cutter or extrudingmechanism closes (i.e., after a product is formed) before the weight ismeasured; (6) the time that the cutter or extruding mechanism remainsopen; (7) the percentage to adjust the pressure by; (8) the amount ofidle time before a screen saver is activated; (9) a password; and (10)the enablement of blowout detection. For example, if the minimum numberof cycles before a pressure adjustment (“Startup Cycles”) is set at two,the system will not make any pressure adjustments until at least thethird extrusion.

[0122] Once the number of cylcles is greater than the “Startup Cycles”,the operation of each cycle proceeds as follows (Note: Blowout detectionis disabled in this description):

[0123] a. The extruder apparatus receives a signal from the cam switch.

[0124] b. The cylinder output is turned on for a specific time. Cylinderoutput is the dwell time (time that the cylinder in the extrudingmechanism is open) to allow for discharge of the dough. For example, theinitialization cylinder output time is a longer duration (e.g., 3.0seconds) than the operational cylinder output time (e.g., 0.75 seconds)to allow any accumulated “older” dough to be discharged before beginninga cycle with a “new” dough.

[0125] c. When the cylinder output turns off, the extruder apparatuswaits for a specific number of seconds before measuring the extrudertank weight. This delay is used for stabilization. The chosen wait timemust be less than the period of time between each cam switch activation.Failure to do this will result in missed extrusions.

[0126] d. The gross weight of the extruder tank is then captured. Datarelating to the gross weight of the extruder tank are transmitted fromthe load cells to the computer. The dispensed weight is calculated(i.e., by subtracting the current gross weight of the extruder tank fromprevious gross weight of the extruder tank) and divided by the number ofactual extruding mechanisms (i.e., does not include extruding mechanismsblocked by baffles) resulting in the actual dispensed weight perdough-based product. The pressure of the tank for the extrusion is alsostored.

[0127] e. Data from the last extrusion (e.g., the dispensed weight andthe tank pressure) and data associated with the current product formula(e.g., target weight, initial tank pressure and feedback adjustment) areused by the computer to determine the pressure for the next extrusion.The computer determines the new pressure using the following formula:${{New}\quad {Press}} = {{{Last}\quad {Press}} - {\left( \frac{{ActualWt} - {TargetWt}}{TargetWt} \right)\left( {{Last}\quad {Press}} \right)({FeedbackAdjustment})}}$

[0128] The actual weight (ActualWt) is the measured or dispensed weightof the extruded dough-based products. The target weight (TargetWt)refers to the desired weight of the dough-based products that is alsostored in a database. The last pressure (LastPress) is the pressure inthe tank for the extrusion that formed the dough-based products havingthe actual weight. The feedback adjustment (“Feedback Adjustment”) is aspecified parameter that correlates the difference in weight to thepressure adjustment.

[0129] f. If the actual or measured weight of the extruded dough-basedproducts is the same as the target or desired weight (i.e.,ActualWt−TargetWt=0), then the pressure is not adjusted. The extruderapparatus then records the cycle number, waits for another signal fromthe cam, and returns to Step a.

[0130] g. If the actual or measured weight of the extruded dough-basedproducts is greater than the target or desired weight (i.e., ActualWt−TargetWt>0), then the pressure is decreased. If the actual ormeasured weight of the extruded dough-based products are less than thetarget or desired weight (i.e., Actual Wt−TargetWt<0), then the pressureis increased.

[0131] h. If the computer determines that a pressure adjustment isnecessary (i.e., ActualWt≠TargetWt), then it transmits a signal to anair pressure controller coupled to a source of air pressure. If the tankpressure is to be increased, the air pressure controller allowsadditional air into the extruder tank. If the tank pressure is to bedecreased, then the air pressure controller will release air from theextruder tank.

[0132] i. The extruder apparatus then records the cycle number, waitsfor another signal from the cam, and returns to Step a.

[0133] The above steps are repeated until the operator presses “STOP.”Subsequent signals from the cam are ignored. The operator then pressesthe “DONE” key to de-pressurize the extruder tank and return to the MAINMENU.

[0134] Various embodiments of the invention have been described infulfillment of the various objects of the invention. It should berecognized that these embodiments are merely illustrative of theprinciples of the present invention. Numerous modifications andadaptations thereof will be apparent to those skilled in the art withoutdeparting from the spirit and scope of the present invention.

That which is claimed:
 1. A method for automatically forming dough-basedproducts, comprising: adding dough to a tank comprising a lid; securingthe lid to the tank; pressurizing the tank containing dough; extrudingthe dough into at least one dough-based product; determining weightdata, wherein determining weight data comprises measuring the weight ofthe at least one dough-based product; comparing the weight data of theat least one dough-based product to a predetermined weight stored in acomputer memory; and adjusting the pressure in the tank based on theweight comparison.
 2. The method of claim 1, further comprisingspecifying at least one process parameter using an input deviceconnected to the computer.
 3. The method of claim 2, wherein thedough-based products are extruded onto trays and wherein each extrusionplaces at least one dough-based product onto a tray.
 4. The method ofclaim 3, wherein a first process parameter is a number of trays to skipafter each extrusion.
 5. The method of claim 1, further comprisingentering a user identification means in a computer.
 6. The method ofclaim 5, further comprising displaying the user identification means. 7.The method of claim 5, further comprising storing data relating to themeasured weight of the dough-based products, the pressure adjustment,and the user identification means.
 8. The method of claim 5, furthercomprising selecting a dough-based product formula from a database. 9.The method of claim 1, wherein securing the lid to the tank comprisesmanually securing the lid to the tank.
 10. The method of claim 1,wherein securing the lid to the tank comprises securing the lid to thetank using an automated tank tightener.
 11. The method of claim 1,wherein the dough-based products are doughnuts.
 12. The method of claim11, wherein the doughnuts are selected from the group consisting ofring-shaped doughnuts, doughnut shells, doughnut twists and cinnamonrolls.
 13. The method of claim 1, further comprising proofing the atleast one dough-based product and frying the at least one dough-basedproduct.
 14. The method of claim 13, further comprising glazing thedough-based products.
 15. An apparatus for automatically formingdough-based products, comprising: an extruder tank comprising a lid andan air inlet, and containing dough; means for securing the lid to theextruder tank; a source of air pressure coupled to the air inlet; acomputer; at least one load cell in communication with the extruder tankand the computer; an air pressure controller in communication with thecomputer and the source of air pressure; and at least one extrudingmechanism for extruding at least one dough-based product.
 16. Theapparatus of claim 15, wherein the means for securing the lid to theextruder tank comprises an automated lid tightener.
 17. The apparatus ofclaim 15, wherein the air pressure controller comprises a transducer.18. The apparatus of claim 15, further comprising a thermometer.
 19. Theapparatus of claim 18, wherein the thermometer measures a doughtemperature.
 20. The apparatus of claim 15, wherein the computercomprises a processor and memory.
 21. The apparatus of claim 20, whereinthe memory comprises data relating to a default setting.
 22. Theapparatus of claim 21, wherein the default setting comprises datarelating to global parameters and data relating to product formulas. 23.The apparatus of claim 22, wherein the memory comprises a program torestore the default setting.
 24. An apparatus for extruding, comprising:an extruder tank for containing dough comprising a lid and an air inlet;means for securing the lid to the extruder tank; a source of airpressure coupled to the air inlet; a computer; at least one load cell incommunication with the extruder tank and the computer; an air pressurecontroller in communication with the computer and the source of airpressure; and at least one extruding mechanism in communication with theextruder tank.
 25. The apparatus of claim 24, wherein the means forsecuring the lid to the extruder tank comprises an automated lidtightener.
 26. The apparatus of claim 24, wherein the air pressurecontroller comprises a transducer.
 27. The apparatus of claim 24,further comprising a thermometer.
 28. The apparatus of claim 27, whereinthe thermometer measures a dough temperature.
 29. The apparatus of claim24, wherein the computer comprises a processor and memory.
 30. Theapparatus of claim 29, wherein the memory comprises data relating to adefault setting.
 31. The apparatus of claim 30, wherein the defaultsetting comprises data relating to global parameters and data relatingto product formulas.
 32. The apparatus of claim 31, wherein the memorycomprises a program to restore the default setting.